Effective predictive maintenance of rotary machinery requires vigilant monitoring of any number of parameters, such as vibration and shock, acoustic emissions, wear debris in oil, etc. Any deterioration of these and other conditions can lead to equipment wear and eventual breakdown if preventive measures are not taken.
Even parts of a machine’s motor that are protected from certain parameters are still susceptible in some regard. For instance, stator windings – stationary windings in an electric motor – are insulated from the motor’s frame, yet the insulation is still affected by all of the stresses present within the motor. Thermal stress is one of the most prominent stresses put on stator winding insulation, as any increases in operating temperature will cause the insulation to age twice as fast.
Aging due to thermal stress breaks down the insulation bonds, creating gas and water due to the thermal agitation of molecules, which can lead to voids in the insulation, reduced adhesion, and eventually, delamination (complete loss of adhesion between insulation layers). Once the insulation is weakened, the mechanical conductor forces can also become an aging factor for the stator winding, exacerbating the insulation’s delamination.
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Replacing an aging stator winding costs significantly less than the lost revenue from downtime experienced after a winding has failed completely. The ability to identify an aging stator winding and replace it before it fails presents a significant value to companies.
One way to monitor the temperature in a rotary machine is to measure in-line temperatures at different points throughout the machine using wireless sensors. In the case of the stator winding, sensors need to be placed as close as possible to the hottest part. By tracking and recording temperature trends, plant managers will know when machine parts are running hot enough to cause issues, and will then be able to address those issues before they lead to catastrophic failure
IoT-based condition monitoring solutions allow for the sensor data to be transmitted to your mobile device or laptop using Parker’s Voice of the Machine™ Software. This allows you monitor not only temperature but other measurements including pressure, humidity, and vibration.
Learn more about these condition monitoring solutions that will save your maintenance team time and resources.
Article contributed by Marc Williams, IoT project lead, Parker Hannifin Corporation
Addition resources on condition monitoring, predictive maintenance and sensors: